BR112019009389B1 - FLOOR PANEL AND METHOD FOR MANUFACTURING A FLOOR PANEL - Google Patents

Abstract

The present invention relates to a floor panel (1) with a substrate (17) comprising thermoplastic material, a decoration (2) provided therein and at least one pair of opposing edges (3-4, 7-8 ), coupling parts (5-6, 9-10) made at least partially from the substrate (17), said coupling parts allowing to effect a mechanical locking between two of these floor panels (1), characterized in that the substrate (17) comprises a rigid substrate layer (17A) of thermoplastic material, and a fiberglass layer (18) is present on the floor panel (1).

Description

[001] This invention relates to a floor panel and a method of manufacturing a floor panel.

[002] More particularly, the invention relates to a floor panel of the type comprising a substrate comprising thermoplastic material and a decoration provided thereon, as well as, at least on a pair of opposite edges, coupling parts realized at least partly from the substrate, said coupling parts allow to effect a mechanical locking, i.e. without using glue or similar, between two of these floor panels. This type of flooring panels makes it possible to form a waterproof floor covering in a smooth and user-friendly way. Such a floor covering can also be applied without any problems in wet rooms such as bathrooms, unlike wood-based laminated flooring panels with, for example, an MDF or HDF substrate, which are less suitable for such applications.

[003] WO 2013/026559 describes such a floor panel, wherein the substrate comprises one or more layers of soft or flexible polyvinyl chloride substrate, abbreviated PVC. However, this floor panel has several problems. For example, there is a not to be overlooked risk of telegraphy effects. Here, after a certain period of time, imperfections in the underlying surface or subfloor on which the panels are installed will become visible on the surface of the panels. When installing the panels in a room with a lot of incident sunlight, such as a balcony or the like, there is also a high risk of edges being pushed up and/or separations forming between the mutually coupled panels. This is the result of the expansion/contraction that the substrate is undergoing with temperature variations. Although the use of a fiberglass layer can increase the dimensional stability of the floor panel, this has often proved insufficient to avoid the aforementioned problems. Furthermore, the panels are relatively flexible and bendable, due to which the installation thereof cannot always be carried out equally smoothly. Furthermore, the lacquer layer present on the upper side of the panel, in most cases proves to be insufficient in the field of wear resistance, scratch resistance, stain resistance and the like.

[004] The floor panel that is known from WO 2014/006593 already addresses a number of the problems mentioned. It has a rigid substrate layer formed by means of extrusion, comprising, on the one hand, high-density polyethylene, abbreviated HDPE or PVC, and, on the other hand, powder from bamboo, wood and/or cork. This substrate layer is glued together with a veneer layer, such as a vinyl decorative layer. This floor panel already offers considerably greater resistance against telegraphy effects. Due to its rigidity, it is also easier to install. However, it also has disadvantages. Therefore, the flatness of the floor panel cannot be guaranteed. There is a considerable risk that it will warp. Furthermore, the floor panel appears to be sensitive to the formation of recesses on its upper side, for example, when table or chair legs are placed on it. Additionally, delamination issues can occur, where the veneer layer separates from the substrate layer.

[005] The invention aims to offer a solution to one or more of the aforementioned and/or other problems.

[006] For this purpose, the invention, according to a first independent aspect thereof, relates to a floor panel of the aforementioned type, with the characteristic that the substrate comprises a rigid substrate layer of thermoplastic material. co and a fiberglass layer present in the floor panel. The inventor has found that applying a fiberglass layer with a rigid substrate layer is extremely advantageous. Provides a reduced risk of panel warping. Furthermore, there is a lower risk of edges and/or separations forming when installing the panels on a porch or similar. The expanding/shrinking is still there however this seems to be less conducive to the last mentioned downside effects. Here, it is noted that expansion as such does not pose a problem, as this can be counteracted by providing the necessary expansion spaces.

[007] It should be noted that, by the term substrate, reference is made to that part of the floor panel that is located under the decoration or possible decoration support.

[008] The rigidity of the substrate layer is preferably obtained by making its thermoplastic material rigid. This possibly using an adequate amount of plasticizer or no plasticizer at all. If plasticizers are used, this is preferably in an amount of less than 15 phr, less than 10 phr or less than 5 phr. Note that an amount of plasticizers of less than 15 phr means that per 100 parts of thermoplastic synthetic material less than 15 parts of plasticizers are present. Examples of plasticizers that can be applied are phthalate-based plasticizers, such as diisononyl phthalate, abbreviated DINP, or dioctyl phthalate, abbreviated DOP or DnOP, or as an alternative to phthalate-based plasticizers, phthalate terephthalate. dioctyl, abbreviated DOTP or diisononyl-1,2-cyclohexane dicarboxylate, abbreviated DINCH.

[009] The thermoplastic material of the rigid substrate layer preferably comprises one or more of the following thermoplastic synthetic materials: PVC, polyethylene, HDPE, polypropylene, polyester, PVC, polyethylene, HDPE, polypropylene, polyester, Poly (Ethylene terephthalate), abbreviated PET, polyurethane and/or elastomer. The most preferred synthetic material is PVC.

[010] The thermoplastic material of the rigid substrate layer preferably comprises an amount of filler. The fillers promote the rigidity of the panels. Various types of fillers can be applied, combined or not: - an inorganic filler, such as chalk, lime and/or talc; - an organic filler, such as wood, bamboo and/or cork; and/or - a mineral filler material.

[011] It is also noted that talc filler is particularly advantageous. Especially, it showed that this load has a positive effect on the dimensional stability of the panel.

[012] The filler percentage is preferably situated between 30 and 70 percent by weight or between 45 and 65 percent by weight. Here, it should be noted that the percentage by weight is considered in relation to the total weight of the thermoplastic material in the substrate layer.

[013] The proportion of filler material is preferably at least 40 percent by weight, more preferably at least 50 percent by weight, and even more preferably at least 60 or at least 70 percent by weight. It showed that such a high proportion of filler increases the dimensional stability of the substrate layer.

[014] The thermoplastic material of the rigid substrate layer may comprise an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black.

[015] It is also noted that the thermoplastic material of the substrate layer may or may not be recycled material.

[016] Preferably, the rigid substrate layer is not or almost not foam. The inventor has discovered that this substrate layer not only offers better resistance against telegraphy effects than foam layers, but also against indentations. It is also noted that almost non-foaming means that the density of the non-foaming thermoplastic material by foaming is reduced by 10% at most, and preferably by 5% at most or by 2% at most. The density of the non- or almost non-foamed substrate layer is preferably between 1300 and 2000 kg per cubic meter or between 1500 and 2000 kg per cubic meter.

[017] However, it is not excluded that the rigid substrate layer is foam. In fact, the inventor found that foam has a positive influence on dimensional stability. Preferably, the density reduction is greater than 10%. This means that the density of non-foaming thermoplastic material is reduced by more than 10% by foaming.

[018] The rigid substrate layer can be formed using various techniques, such as spreading, extrusion or calendering processes. The spreading process, which as such is known from WO 2013/179261 and BE 2015/5572, is preferred. In fact, the flatness of the substrate layer can be better guaranteed by such a process.

[019] The fiberglass layer may refer, for example, to a fiberglass fleece, a fiberglass fabric or a fiberglass net.

[020] The fiberglass layer is preferably adjacent to the rigid substrate layer. In this position, the fiberglass layer can better counteract possible warping or dimensional deformation of the substrate layer.

[021] The fiberglass layer is preferably at least partially impregnated with a thermoplastic material of the rigid substrate layer. This provides a good incorporation of the fiberglass layer, due to which its work is more efficient. The risk of delamination is also reduced.

[022] It is also noted that the fiberglass layer preferably refers to a fiberglass fleece. This type of fiberglass layer bonds best with the substrate layer. Better impregnation is also possible.

[023] The substrate may comprise a second rigid substrate layer of thermoplastic material. This substrate layer may show one or more of the characteristics of the first mentioned substrate layer.

[024] Preferably, the fiberglass layer is adjacent to the aforementioned first as well as the second substrate layer. Here, the fiberglass layer is situated between the two substrate layers. This can be achieved in different ways.

[025] It is preferable that the two layers of rigid substrate are provided by means of a spreading treatment. In this case, one substrate layer can be spread, the fiberglass layer can be provided over it and the other substrate layer can be spread over this complex. Later, the whole can be consolidated. Such a process is known as such from WO 2013/179261. It offers the advantage that the fiberglass layer can be embedded very well between the two substrate layers.

[026] Another possibility is that in which the substrate layer is provided by means of a spreading treatment, the fiberglass layer is provided over it, this complex is consolidated and the other layer of substrate is only then provided over it. this consolidated complex. Such a process is known from WO 2016/079225. It offers the advantage that the risk of deformation and/or damage to the fiberglass layer can be minimized, since a printing element of the possibly employed printing device can be directed directly onto the fiberglass layer. The other substrate layer can be provided, for example, by means of a calendering technique.

[027] Yet another possibility is to manufacture the two layers of rigid substrate by extrusion. In that case, the extruded substrate layers and the fiberglass layer can be stacked on top of each other and subsequently bonded to each other. Mutual bonding can be carried out in a pressing device, for example in a multiple-day or single-day pressing.

[028] Another option is to form the single layer of substrate by means of extrusion, transporting this layer of extruded substrate and providing the fiberglass layer during said transport over said layer of extruded substrate. An advantage of this process over the previous one is that it can be run continuously. For example, a substrate layer can be conveyed along guide rollers and the fiberglass layer can be fed along with the substrate layer between these guide rollers. The other substrate layer can be provided later on the fiberglass layer. Or it is possible to supply this substrate layer together with the fiberglass layer on top of the substrate layer during its transport.

[029] The fiberglass layer may not be treated. However, it is also possible for the fiberglass layer to be pre-treated. The latter can provide better bonding with the substrate layer or layers to which the fiberglass layer is adjacent. The pretreatment may include providing a coating on the fiberglass layer or impregnating the fiberglass layer. The coating or impregnating material may refer to a plastisol, preferably a PVC plastisol. Pre-treatment can take place in an off-line step.

[030] The weight of the fiberglass layer can be between 30 and 100 grams per square meter. However, preferably this weight is less than 65 grams per square meter. This offers the advantage that the fiberglass layer can be incorporated more easily and quickly into the substrate. Furthermore, this lighter fiberglass results in only a slight to no reduction in dimensional stability, at least not like that applied with rigid substrate layers, as the inventor unexpectedly discovered.

[031] In the floor panel, preferably, a second layer of fiberglass is present. Using more than one layer of fiberglass proved to be more effective than using a single layer of fiberglass. The second fiberglass layer may show one or more of the characteristics of the first mentioned fiberglass layer.

[032] In particular, both the first and second fiberglass layers have a weight of less than 65 or at most 50 grams per square meter. This has a positive influence on processing speed and practically no detrimental influence on dimensional stability, at least not when applying with rigid substrate layers.

[033] The two layers of fiberglass are preferably located away from the center of the floor panel. In this way, its effect is better distributed across the floor panel. Preferably, the single layer of fiberglass is located in the bottom half of the floor panel, while the other layer of fiberglass is located in the top half.

[034] The two fiberglass layers are preferably located at a vertical distance from each other of at least 1/5 or at least 1/4 of the thickness of the floor panels. This provides a good distribution of the effect of the fiberglass panels over the total thickness of the floor panel. More preferably, they are situated at a vertical distance from each other of approximately 1/3 of the thickness of the floor panel.

[035] Preferably, the two layers of fiberglass surround the first substrate layer. Here, its upper side is delimited by one layer of fiberglass, and its lower side by another layer of fiberglass. The thickness of the first layer of substrate in this case is preferably at least 1/5, at least 1/4 or approximately 1/3 of the total thickness of the floor panel. The two fiberglass layers are preferably located spaced apart from the center of the floor panel, such that the centerline of the floor panel in this case runs through the first layer of substrate.

[036] The single fiberglass layer is preferably wrapped between the first substrate layer and a second rigid substrate layer of thermoplastic material, while the other substrate layer is preferably wrapped between the first substrate layer and a third layer Rigid substrate of thermoplastic material. This results in a particularly balanced and stable sandwich structure. The second and third substrate layers can show one or more of the characteristics of the first substrate layer. The first substrate layer is preferably centrally located, i.e. the centerline of the floor panel runs through it, while the second and third substrate layers are preferably centrally located, with the second substrate layer in the top half and the third substrate layer in the bottom half of the floor panel. The second and third substrate layers are preferably thinner than the first substrate layer, however preferably their thickness is at least 1/5 or at least 1/4 of the thickness of the first substrate layer . The third substrate layer is preferably made thicker than the second substrate layer, however at most 2.5 or at most twice as thick.

[037] One or more layers of rigid substrate of thermoplastic material form a rigid part of the floor panel. This rigid part preferably has a total thickness of at least 2 mm. In other words, the inventor found that, starting from this thickness, the resistance against telegraphy effects and the flexural rigidity is very good. Even better the total thickness of the rigid part is at least 2.5mm or at least 3mm. The total thickness of the rigid part is preferably 8 mm maximum, 6 mm maximum or 4 mm maximum. In this way, the weight of the panels can remain limited. The total thickness of the rigid part is preferably between 2 and 8 mm, between 2 and 6 mm or between 2 and 4 mm. The total thickness of the rigid part is preferably at least 50%, at least 60% or at least 65% of the total thickness of the floor panel.

[038] The substrate preferably comprises a substrate layer that is more flexible or compressible than the first rigid substrate layer. This more flexible substrate layer offers the advantage that the sound, which is created when the installed flooring panels are walked on, can be dampened. Preferably, this flexible substrate layer is situated between the first substrate layer and the decor. Preferably, this more flexible substrate layer is situated directly under the decoration or possible decoration carrier on which the decoration is provided. In this case, it also helps to efficiently obtain deep relief structures on the upper side of the floor panel. For this purpose, it is in fact desirable to deform the material underneath the decoration, which is easier when this material is relatively flexible.

[039] The most flexible substrate layer is preferably constructed of thermoplastic material, where PVC is best used as a thermoplastic synthetic material, however, where the use of other synthetic materials, such as polyethylene, polypropylene, polyester, such as such as PET, polyurethane and/or elastomer is not excluded. The flexibility of this substrate layer is preferably achieved by making its thermoplastic material soft or semi-rigid. This is possible using an appropriate amount of plasticizers, certainly in the case where PVC is applied as thermoplastic synthetic material. The amount of plasticizers in the more flexible substrate layer is preferably at least 15 phr and even better at least 20 phr. Examples of plasticizers that can be used, certainly in the case of PVC, are phthalate-based plasticizers such as DINP or DOP, or, as an alternative to phthalate-based plasticizers, DOTP or DINCH.

[040] When making the substrate layer more flexible, an extrusion, calendering or spreading technique can be applied.

[041] It is preferable that the most flexible substrate layer is bonded to the first or possible second rigid substrate layer by means of thermal lamination, which, compared to the use of glue or the like, restricts the risk of delamination. Preferably, this is carried out by a calendering process, for example by means of a calendering device consisting of more than two calendering rolls.

[042] However, it is not excluded that the most flexible substrate layer is composed of a material other than the thermoplastic material. For example, it is possible that this substrate layer relates to a carpet layer, or to a textile layer in general, i.e. made of rubber or cork. In these cases, it is preferred that the respective substrate layer is connected to the first or second possible rigid substrate layer by means of glue or the like, preferably a waterproof glue, such as hot melt glue. Here, it is also noticed that in the case of, for example, a layer of carpet, the decoration is actually included in this layer of carpet.

[043] The thickness of the most flexible substrate layer is preferably between 0.5 and 3 mm, even better between 0.5 and 2 mm, and better between 0.5 and 1 mm, even better between 0.5 and 2 mm and better between 0.5 and 1 mm, or between included limits, as with these thicknesses the advantages described above will be shown particularly well.

[044] The substrate may comprise a substrate layer on its underside, which layer is preferably more flexible or more compressible than the first rigid substrate layer. Because of such a layer of substrate situated on the underside of the substrate, the advantage is obtained that the noise which is created when the installed floor panels are walked on can be dampened. This substrate layer can be composed of thermoplastic material, where the use of synthetic materials, such as PVC, polyethylene, polypropylene, polyester, such as PET, polyurethane and/or elastomer, is possible. The respective substrate layer is preferably foam, considering that this can improve its sound absorption characteristics. A preferred embodiment of such a substrate layer is one comprising XPE or cross-linked polyethylene foam.

[045] When embodying said layer of substrate located on the underside of the substrate, an extrusion, calendering or spreading technique can be used.

[046] It is an option to bond this layer of substrate with the first or possible third layer of rigid substrate by thermal lamination, which, compared to the use of glue or the like, restricts the risk of delamination. However, it is not excluded that the respective substrate layer is bonded to the first or possible third substrate layer in another way, such as with glue or the like, in which case a waterproof glue, such as hot melt glue, is preferably used. .

[047] It is also not excluded that the reinforcement layer is composed of a material other than thermoplastic material. For example, it is possible that the reinforcement layer is related to a textile layer or is composed of cork or rubber. In these cases, it is preferred that the reinforcing layer is attached to the core by means of glue or the like, preferably a waterproof glue such as hot melt glue.

[048] The thickness of said layer of substrate located on the underside of the substrate is preferably between 1 and 4 mm, even better between 1 and 3 mm and better between 1 and 2 mm, limits included, where a thickness of approximately 1 .5 mm proved ideal.

[049] Decoration preferably refers to a printed or printed decoration, where this printed or printed decoration best describes a natural product, such as wood or stone. In the case of wood, the decoration can represent, for example, wood fibers and/or wood pores. For printing or stamping, any of the following techniques can be used: offset printing, gravure printing and a digital printing technique, where, for example, a digital press or inkjet printer is used.

[050] The decoration can be printed or stamped on a decoration support. Or the decor can be printed or stamped directly onto the substrate, in which case this relates to so-called "direct printing". Here, it is possible for the substrate to be provided with a base coat or base paint, possibly a plurality of base coats or paints, before printing or stamping thereon.

[051] When the decoration is printed or stamped on a decoration support, this preferably refers to a sheet or film, which can be thermoplastic. This may relate, for example, to a PVC, polyethylene, polypropylene, polyurethane or polyester film or sheet such as PET.

[052] It is also possible that the decoration support relates to a cellulose-based layer, preferably impregnated with a resin. For example, cellulose-based layer refers to paper such as standard paper or Kraft paper. The resin preferably comprises melamine resin and/or a phenolic resin.

[053] It is also noted that, in the case where the decoration support refers to a cellulose-based layer, also one or more cellulose-based layers, such as paper, may be present underneath, which improves rigidity of the floor panel. These or more additional cellulose-based layers are preferably impregnated with resin, such as melamine and/or phenolic resin.

[054] As an alternative to a printed or stamped decor, for example, a wood or stone veneer can be provided over the substrate, which then forms the decor. Preferably, the possible wood laminate is treated in such a way that it is waterproof or predominantly waterproof.

[055] Preferably, the floor panel comprises a wear layer and/or varnish layer provided over the decoration to protect the decoration and to prevent it from wear. Preferably, these layers are transparent or translucent, such that the decoration remains visible.

[056] The wear layer preferably refers to a sheet or film, which is better thermoplastic. This may relate, for example, to a PVC, polyethylene, polypropylene, polyurethane or polyester film or sheet such as PET. The thickness of such sheet or film preferably lies between 250 and 750 micrometers, limits included. This type of wear layer is preferably applied in the case where the decoration is printed or embossed on a sheet or film.

[057] It is also possible that the wear layer relates to a cellulose-based layer, preferably impregnated with a resin. For example, the cellulose-based wear layer refers to paper, such as standard paper or Kraft paper. The resin preferably comprises melamine resin and/or a phenolic resin. Preferably, the cellulose-based wear layer comprises wear resistant particles such as ceramic or corundum particles. This type of wear layer is preferably applied when the decoration is printed or embossed on a cellulose based layer.

[058] The varnish layer is preferably based on urethane acrylates, polyester acrylates and/or epoxy acrylates. Preferably, this refers to a varnish layer which can be cured by means of UV radiation or excimer radiation (Excimer laser). The lacquer layer may comprise ceramic particles such as aluminum oxide and/or silica. The varnish layer can be provided before or after forming the possible relief on the upper side of the floor panel. Of course, with a rather deep relief, for example the relief reaching more than 100 or 250 microns, it is advantageous to provide the varnish layer before forming the relief, as known from document BE 2016/5732, considering that this helps to avoid interruptions in the varnish layer. This certainly proves useful when applying high-gloss wear layers such as PVC wear layers, as in this way the occurrence of flashing spots resulting from such wear layers can be avoided, as described in BE 2016/ 5732.

[059] It is also noted that a plurality of layers of varnish may be present above the decoration. This is particularly advantageous in the case where a relief is provided on the upper side of the floor panel. In that case, a first layer of varnish may be provided before the formation of the embossing, in order to ensure that this layer of varnish does not show any interruptions and to avoid the occurrence of blinking spots, and a second one after the embossing has been formed, in that for this second layer of varnish a harder layer of varnish can be applied, the principle of which is known as such from BE 2016/5732.

[060] It is also noted that the invention allows the application of harder varnish layers. This is due to the presence of the rigid substrate layer. In fact, this substrate layer can neutralize the curling to which the varnish layer is subjected, without the panel warping or deforming. Applying harder lacquer layers offers the advantage of being more effective and providing better mechanical and chemical resistance.

[061] The upper side of the floor panel can show a relief simulating the texture of a natural product, such as wood, stone or ceramics. In the case of wood, the relief can simulate, among others, wood fibers and/or wood pores. Possible chamfers on one or more edges of the upper side of the floor panel do not belong to this relief and are not considered as part of the relief, in view of the fact that they are not intended to simulate a natural texture, but rather to achieve an effect board. Embossing can be provided by mechanical and/or chemical etching.

[062] The relief preferably has a maximum relief depth that is greater than 100 microns and even better is greater than 200 or 250 microns. This deep relief allows the floor panel to look and feel very natural. With such deep relief, it is particularly advantageous when a more flexible substrate layer, as described above herein, is applied. In fact, this substrate layer can be easily deformed or printed in order to form the deep relief.

[063] In case a relief is formed on the upper side of the floor panel, it is better to have a wear layer in which the relief extends. It is possible that the relief, certainly with a deep relief, extends into the wear layer, however, into the substrate, preferably into the possible more flexible substrate layer.

[064] The relief may or may not be made in line with the decoration. Running on register carries the advantage of achieving a more natural looking and feeling floor panel. Several techniques are known to carry out this incorporation "on record", in particular from the following documents: EP 2 636 524, EP 2 447 063 and EP 2 447 064.

[065] Note that in the case where a wood or stone veneer is provided above the substrate, the upper side of the floor panel is automatically embossed with the texture of wood or stone, respectively.

[066] The upper side of the floor panel may comprise a bevel on one or more edges thereof. This could be related to a bevel not reaching deeper than the possible wear layer. However, it is possible for the bevel to reach deeper than the wear layer, for example into the substrate, in which case the bevel is preferably decorated. This is possible by providing a separate decoration on the bezel, i.e. a decoration separate from the decoration, such as a layer of varnish, ink or transfer foil. Or the decoration can extend uninterruptedly over the bezel. If so, this may be related to a so-called "pressed bevel", where the bevel is formed by pressing the upper side of the floor panel, including the decor, close to an edge thereof.

[067] The floor panel preferably shows one or more of the following characteristics:

[068] - the floor panel sags under its own weight less than 10 cm per meter and even better less than 5 cm per meter; and/or

[069] - the floor panel has a modulus of elasticity or a Young's modulus of at least 2000 N per square millimeter, at least 3000 N per square millimeter or finally 3500 N per square millimeter.

[070] The bending can be measured by clamping the floor panel at one end of it and measuring the bending of the remaining free part. In the case of an oblong rectangular panel, the fixedly secured end may refer, for example, to one of the longitudinal ends.

[071] The modulus of elasticity should be understood as that at an ambient temperature of 25 degrees Celsius.

[072] The total thickness of the floor panel is preferably between 3 and 10 mm, or between 3 and 8 mm, or between 3.5 and 8 mm, or between 3.5 and 6 mm, or between 4 and 6 mm, limits included, where an ideal thickness is approximately 4.5 mm.

[073] The mechanical locking effected by the coupling parts in the condition of coupling two of these floor panels can be operative at least or exclusively in the horizontal direction, that is, the direction in the plane of the coupled peak panels that is perpendicular to the coupled edges. This horizontal locking can be realized by cooperating with locking surfaces. The zone in which these locking surfaces cooperate is preferably located at least partially or entirely on the first, the possible second or the possible third layer of rigid substrate, which offers the advantage of being able to provide a strong locking and the formation of separations can be minimized. It is also possible to place the fiberglass layer at the height of this area, which improves blocking resistance.

[074] The mechanical locking effected by the coupling parts in the condition of coupling two of these floor panels can be operative at least or exclusively in the vertical direction, that is, the direction perpendicular to the plane of the coupled floor panels. This horizontal locking can be carried out by the cooperation of locking surfaces, wherein the zone in which these locking surfaces cooperate is preferably located at least partially or entirely on the first, the possible second or the possible third layer of rigid substrate, which offers the advantage that it can provide strong locking and the formation of separations can be minimized. It is also possible to place the fiberglass layer at the height of this area, which improves blocking resistance.

[075] It is preferable that both a horizontal and a vertical locking are present, best accomplished by cooperating locking surfaces, in which the zone or zones in which the locking surfaces cooperate are preferably situated at least partially on the first, as far as possible second or possible third layer of rigid substrate. The fiberglass layer can be located at the height of an area where the locking surfaces cooperate. In case there are a plurality of zones in which interlocking surfaces cooperate, these fiberglass layers, when using a plurality of fiberglass layers, or at least a part of these fiberglass layers, can be located at the height of the above-mentioned areas.

[076] The coupling parts can be realized as a tongue and groove connection, the groove being delimited by an upper and a lower lip. This connection preferably comprises locking elements, for example in the form of a protrusion on the lower side of the tongue and a recess on the upper side of the lower lip, which, in the coupled condition, counteracts the movement of the tongue and the slot in the horizontal direction. Preferably, this tongue and groove connection shows one or more of the following characteristics, in so far as they are not contradictory, characteristics that increase the stability and strength of the locking: - the upper lip is at least partially realized from the first or the possible second rigid substrate layer; - the lower lip is at least partially made from the first or possible third layer of rigid substrate; - the center line through the tongue is located on the first rigid layer of substrate; - the innermost point of the groove is located in the first layer of rigid substrate; - the zone where the upper side of the tongue cooperates with the lower side of the upper lip is situated at least partially or entirely on the first or possible second rigid substrate layer; - the zone where the possible locking elements cooperate is located at least partially or totally in the first or possible third rigid substrate layer; - the fiberglass layer is located at the height of the area where the upper side of the tongue cooperates with the lower side of the upper lip; - the fiberglass layer is located at the height of the area where the possible locking elements cooperate; - the fiberglass layer is located on the centerline across the tongue; - the fiberglass layer is located at the height of the most internally located groove point; - in case the area where the upper side of the tongue cooperates with the lower side of the upper lip is located in a different location than the area where the possible locking elements cooperate, preferably at least two layers of fiberglass are present, characterized due to the fact that it is preferable that the single fiberglass layer is located at the height of the area where the upper side of the tongue cooperates with the lower side of the upper lip, and the other is located at the height of the area where the possible locking elements cooperate; - the fiberglass layer extends uninterruptedly or continuously across the lower or upper lip; and/or - the fiberglass layer extends uninterruptedly or continuously on at least one of the coupling parts.

[077] The coupling parts realized as tongue and groove connection are preferably selected from the following types: - the type in which the coupling parts are configured in order to allow the coupling of two of these floor panels in the respective ends by means of a rotational movement, whereby the floor panel with the tongue, from an inclined position in which the tongue which is already partially located in the groove, is turned downwards in order to make the tongue entering completely into the groove and coupling the respective edges to each other; - the type in which the coupling parts are configured in such a way as to allow the coupling of two such floor panels at the respective edges by means of a substantially linear movement in the plane of the floor panels and substantially perpendicular to the respective edges, preferably with performing an instant action; - the type in which the coupling parts are configured so as to allow the coupling of two such floor panels at the respective edges both by means of a rotational movement as described above and by means of a substantially linear movement in the plane of the floor panels floor and substantially perpendicular to their edges, preferably by performing an instant action.

[078] It is also noted that the tongue and groove connection, in the case where the floor panel is rectangular, square or oblong rectangular, can be applied to each of the pairs of opposite edges of the floor panel.

[079] As an alternative, the coupling parts can be realized in the form of hook-shaped parts, consisting, on the one hand, of a hook-shaped locking part directed upwards with a lip and a locking element directed upwards and, on the other hand, a hook-shaped part directed downwards with a lip and a hook-shaped part directed downwards, which locking elements, in the coupled condition of two such floor panels, counteract the spacing of the hook-shaped parts in the horizontal direction. The mechanical locking effected by these hook-shaped parts is preferably also operative in the vertical direction, and for this purpose they can be provided with vertically active locking elements. Preferably, the hook-shaped parts show one or more of the following characteristics, which characteristics all improve the stability and strength of the locking: - the lip of the downwardly directed hook-shaped part is at least partially realized from the first or the possible second rigid substrate layer; - the lip of the upwardly directed hook-shaped part is at least partially made from the first or possible third layer of rigid substrate; - the zone where the locking element directed upwards cooperates with the locking element directed downwards in order to effect the horizontal locking, is located at least partially or totally in the first or in the possible third layer of rigid substrate; - the zone or zones where the possible vertically active locking elements cooperate, is located at least partially or totally in the first, in the possible second or in the possible third rigid substrate layer; - the fiberglass layer is located at the height of the area where the locking element directed upwards cooperates with the locking element directed downwards in order to effect the horizontal locking; - the fiberglass layer is located at the height of the zone or zones where the possible vertical blocking elements cooperate; - in the case where the zone, in which the locking element directed upwards, cooperates with the locking element directed downwards in order to effect the horizontal locking is located in another location than in a zone where the possible elements vertically active locking elements preferably cooperate at least two layers of fiberglass are present, it being preferably valid that the only layer of fiberglass is located at the height of the zone where the locking element directed upwards cooperates with the locking element locking directed downwards in order to effect the horizontal locking, and the other is located at the height of the zone where the possible vertically active locking elements cooperate; the fiberglass layer extends uninterruptedly or continuously on the lip of the downwardly directed hooked portion or on the lip of the upwardly directed hooked portion; and/or - the fiberglass layer extends uninterruptedly or continuously on at least one of the hooked parts.

[080] The vertically active locking elements may or may not comprise a separate insert, preferably an elastically deformable and/or mobile insert, which as such is known, inter alia, from WO 2006/043893, WO 2008/068245 and WO 2009/066153. The insert offers the advantage that the strength of the vertical locking is largely independent of the material of the floor panel itself and that a stronger vertical locking can mainly be provided compared to locking elements that are made from the material of the floor panel itself. floor panel. Certainly, with regard to reducing the risk of gaps forming between mutually coupled floor panels, such an insert is therefore useful.

[081] The insert is preferably provided in a recess in the hook-shaped part directed upwards or downwards. This recess is preferably located at least partially in the first rigid substrate layer.

[082] In case no use is made of such an insert, the vertically active locking elements are preferably made from the material of the floor panel itself and even better from the material of the first, possible second or possible third layer of substrate rigid.

[083] The rigid character of these substrate layers allows these locking elements to also provide a strong vertical locking.

[084] The hook-shaped parts can preferably be engaged with each other by means of a substantially linear movement perpendicular to the plane of the coupled floor panels or the plane of the floor covering.

[085] It is also noted that the hook-shaped parts, in the case where the floor panel is square or oblong rectangular, can be applied to each of the pairs of edges of the floor panel.

[086] Preferably, the floor panel is square or oblong rectangular and can be coupled to adjacent floor panels by means of the folding technique. For this purpose, this floor panel comprises, on the one hand, a pair of opposite edges, coupling parts which are realized in the form of a tongue and groove connection and which are of the type that allows coupling this floor panel to an already existing installed, similar floor panel, located in a preceding row, by means of a turning movement and, on the other hand, on the other pair of edges, hooking parts that are realized in the form of hook-shaped pieces and that allow to couple the respective floor panel, in one and the same turning movement, to an already installed similar floor panel situated in the same row. It has shown that this folding technique is excellently suited for installing the floor panel according to the invention.

[087] It is also noted that, instead of a fiberglass layer, any reinforcing layer can be applied. Preferably, this is a reinforcing layer comprising reinforcing fibres, such as carbon fibres.

[088] According to a second independent aspect, the invention relates to a floor panel of the above-mentioned type, with the feature that the substrate comprises a rigid substrate layer, not foam, of thermoplastic material. Hereby, the floor panel, compared to floor panels with foamy substrate layers, is less sensitive to indentation effects, for example under the influence of chair and/or table legs.

[089] Note that this advantage also shows in the case where the rigid substrate is hardly foaming, that is, in the case where, due to foaming, the rigid substrate layer has a maximum density reduction of 10% .

[090] According to a third independent aspect, the invention relates to a floor panel of the above-mentioned type, with the feature that the substrate comprises a substrate layer of thermoplastic material, which, by thermal lamination, is bonded to a more flexible substrate layer located between the decoration and the rigid substrate layer. By this means, the risk of delamination is reduced.

[091] According to a fourth independent aspect, the invention relates to a floor panel of the aforementioned type, with the feature that at least two layers of fiberglass are present in the floor panel, each with a weight of less than 65 g per square meter or even a maximum of 50 g per square meter.

[092] It is also noted that each of the second and fourth aspects can be combined with one or more of the features of the first aspect without requiring the floor panel to show the feature of this first aspect.

[093] According to a fifth independent aspect, the invention relates to a method for manufacturing a floor panel with a substrate, comprising thermoplastic material and a decoration provided therein, wherein the method comprises the following steps: - providing a first rigid substrate layer of thermoplastic material by means of a first spreading treatment; - providing a fiberglass layer over the spread substrate layer; - providing a second rigid substrate layer of thermoplastic material over the fiberglass layer, by means of a second spreading treatment; - consolidating the spread substrate layers and the fiberglass layer under the influence of pressure and/or heat; - providing over the second layer of consolidated substrate, a more flexible or more compressible substrate layer of thermoplastic material by applying this thermoplastic material in liquid state.

[094] The particularity of the method is that the rigid substrate layers are consolidated and only then is the most flexible substrate layer provided over them. This makes it possible to adjust the consolidation parameters, such as pressure and/or temperature, in an optimal way depending on the characteristics of the thermoplastic material of the rigid substrate layers, which are different from those of more flexible substrate layers, considering the difference in rigidity/flexibility.

[095] The thermoplastic material of the first and/or second substrate layer can be spread in the form of grains or powder. Preferably, this material, or at least a part of it, is spread in granulated form, however, it can be advantageous to spread it as a dry mix, certainly in the case where this material, or part of it, must be be foamy.

[096] This dry mixture guarantees, in fact, the characteristics of the foaming agents added to the material, as described in document BE 2015/5572, in a better way.

[097] Consolidation can be carried out on a pressing device, preferably a double belt press device. This press device may comprise an S-roller, which may provide a calibration of the spread material.

[098] Preferably, the more flexible substrate layer is provided on the second substrate layer by means of a calendering device. The calendering device preferably comprises more than two calendering rolls.

[099] It is clear that the method may also comprise providing the decoration and possible wear layers and/or varnish layer.

[0100] The aforementioned layers preferably form a network of continuous material, which is finally divided into individual pieces, for example by means of cutting treatments, to form the floor panels.

[0101] After dividing into individual parts, the floor panels, along one or more edges, can be provided with coupling parts that allow for a mechanical coupling between two of these floor panels. The provision of these coupling parts is preferably carried out by means of cutting tools, such as milling tools.

[0102] The floor panel that is obtained according to the invention may further show one or more of the characteristics of the floor panel according to said first, second, third and/or fourth aspects.

[0103] Note that the present invention is not only applicable with floor panels. It can advantageously be applied to any type of panels, such as wall panels, ceiling panels or door panels.

[0104] The invention can also be applied more broadly than just with panels. It can be advantageously applied to any type of floor, wall, ceiling or door elements. Examples thereof are roll flooring elements or wall-to-wall flooring elements such as wall-to-wall vinyl.

[0105] It is also noted that with each of the ranges of values mentioned the limits are included if not explicitly stated otherwise.

[0106] With the intention of better showing the characteristics of the invention, here below, as an example without any limitation, some preferred embodiments are described, with reference to the attached drawings, in which: - Figure 1 represents a floor panel of according to the invention; - figure 2 represents a cross-section according to the line ll-ll of figure 1; - Figures 3 and 4 represent how the edges of Figure 2 can be coupled; - Figure 5, on a larger scale, represents what is indicated by F5 in Figure 2; - figures 6 and 7 represent variants of figure 2; - Figures 14 and 15 represent how the floor panels can be joined according to the fold-down technique; - figure 16 represents coupling parts that can be applied with such folding floor panels; - Figures 17 to 19 represent variants of Figure 16; - figure 20 represents a method according to the invention; and - Figures 21 and 22 represent variants.

[0107] Figure 1 represents a floor panel 1 according to the invention. The represented floor panel 1 comprises a decor 2, which refers to the embossed wood decor. This refers to an oblong rectangular floor panel 1, which as a result has a pair of long edges 3-4 and a pair of short edges 5-6. Each pair of edges is supplied with coupling parts, which are indicated by reference numbers 7-8 and 9-10 respectively.

[0108] The shape of the coupling parts 7-8 is evident from Figure 2. This refers to a tongue and groove connection comprising a tongue 11 and a groove 12, the groove being surrounded by an upper lip 13 and a lower lip 14. The lower lip 14 protrudes beyond the upper lip 13. Additionally, the connection comprises locking elements 15-16 in the form of a protrusion 15 on the underside of the tongue 11 and an upwardly directed locking element 16 on the part of the lower lip 14 projecting beyond the upper lip 13, which, by cooperating with the locking surfaces 17-18, counteracts movement of the tongue 11 and groove 12 in the horizontal direction H. The upper side 19 of the tongue 11 cooperates with the underside 20 of the upper lip 13 to counteract separation in the vertical direction V.

[0109] Figures 3 and 4 show how the coupling parts 7-8 can be coupled by means of a rotational movement (Figure 3) as well as a substantially horizontal fitting movement (Figure 4).

[0110] Figure 2 also shows the construction of the floor panel 1. It is constructed of a substrate 21, a decoration support 22 with decoration 2, a wear layer 23 and a varnish layer 24.

[0111] The substrate 21 consists of two substrate layers 21A and 21B made of PVC.

[0112] The substrate layer 21A is rigid. For this purpose, no plasticizers are present in this layer 21A, or plasticizers are present in an amount of less than 15 phr only. Examples of plasticizers that can be used have already been mentioned. Furthermore, the substrate layer 21A comprises a filler proportion between 30 and 70 percent by weight. Preferably, chalk, talc and/or lime is used, possibly supplemented with wood, bamboo and/or cork particles. Furthermore, substrate layer 21A may comprise an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black. The thickness T1 of the substrate 21A is at least 2 mm. The result is that substrate layer 21A has high flexural rigidity. This is advantageous, considering that the risk of deformation of the floor panel 1 and the formation of edges pushed upwards under incident sunlight is already neutralized to some extent.

[0113] This risk is significantly reduced further due to the presence of the fiberglass fleece 25. While it does not appear to be able to prevent expansion/shrinkage of the substrate 21 with varying temperatures, it effectively counteracts warping or upward thrusting. This is indeed the most important thing, considering that expansion/shrinkage as such can be counteracted by providing adequate expansion spaces, which are also known as such in the field of laminate wood flooring. Fiberglass fleece 25 is wrapped between substrate layer 21A and 21B. In this way, it can perform its function at its best. Possibly, fiberglass fleece 25 is at least partially impregnated with thermoplastic material from substrate layers 21A and/or 21B. This provides strong incorporation into substrate 21 such that it can perform its function even better. The position of the fiberglass layer 25 provides for it to extend uninterruptedly on both coupling parts 7-8. This is positive for its effectiveness, certainly on the respective edges 3-4 of panel 1.

[0114] The rigid substrate layer 21A is obtained through a spreading process. By such a process, a very good connection with the glass fleece 25 can be obtained. In this process, the glass fleece 25 can also have a support function. Possibly, the glass fleece 25 can also form a separation between the spread layer 21A and the layer 21B in case the latter is also spread. This is certainly useful before consolidation, as this prevents a mutual mixing of the material spread between the layers.

[0115] Furthermore, the substrate layer 21A is not foam. Compared to foam layers, this provides better resistance against telegraphy and recess effects. The density of layer 21A is between 1300 and 2000 kg per cubic meter.

[0116] The area where the upper side 19 of the tongue and the lower side 20 of the upper lip cooperate is located entirely on the rigid substrate layer 21A, as is the area where the locking elements 15-16 cooperate. This provides that a strong mechanical coupling can be effected, whereby the formation of separations will arise less easily. The upper lip 13 is partially made from layer 17A, and the lower lip 14 is entirely the same. This provides a reduced risk of breaking one or both labia 13-14. Of course, with the lower lip 14, this is advantageous, since this lip 14 cannot break as a result of the possible bending to which it is subjected during the coupling of the edges 3-4. Otherwise, the coupling will be lost.

[0117] The substrate layer 21B is more flexible than the layer 21A. For this purpose, in this layer 21B more plasticizers are present, that is, at least 15 phr. This flexible layer 21B prevents that, apart from the relatively rigid panel 1, no ticking sound is created when this panel 1 is stepped on. Thus, due to the soft character, it has sound-absorbing properties. Furthermore, this layer 21B is easier to deform so as to create a deep relief on the upper side of the panel 1. The filler proportion in this layer 21B is between 30 and 70 percent by weight. Furthermore, substrate layer 21B may comprise an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black. The thickness T2 of substrate layer 21B is between 0.5 and 1 mm.

[0118] Layers 17A and 17B are bonded to each other by means of thermal lamination. In this way, a reduced risk of delamination is obtained compared to the use of glue or the like.

[0119] The decoration support 22 on which the decoration is stamped refers to a PVC film or sheet.

[0120] The transparent wear layer 23 refers to a PVC layer with a thickness between 250 and 750 micrometers.

[0121] The total thickness T of floor panel 1 is between 3.5 and 6 mm.

[0122] Figure 5 better shows the lacquer layer 24 that is provided in the wear layer 23. This refers to a lacquer layer produced on the basis of urethane acrylate. The relief 26 provided on the upper side of the panel 1 is also visible.

[0123] Figure 6 shows the coupling parts 7-8 similar to those in figure 2, however, the substrate 21 is constructed differently. Layer 21A is constructed similarly to layer 21A in Figure 2, however thinner. Anyway, a second rigid substrate layer 21C is also present on the substrate 21, which is also made of PVC. Substrate layer 21C does not contain plasticizers or plasticizers in an amount less than 15 phr. Substrate layer 21C also comprises a filler proportion between 30 and 70 weight percent. Furthermore, substrate layer 21C may comprise an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black. The total thickness T1 of substrate layers 21A and 21C is at least 2 mm. The result is that the totality of both substrate layers 21A and 21C gives a high flexural rigidity to the panel 1, which is even increased by the included glass fleece 25. The position of the glass fleece 25 is such that it extends uninterruptedly. through both coupling parts 7-8. And it is positioned at the height of the center line of the tongue 11 and crosses the innermost point of the groove 12. Thus, in these places additional support is given, which is beneficial for the resistance of the tongue 11 and the groove 12.

[0124] Rigid layers 21A and 21C are formed by means of a spreading process which is known as splinting from WO 213/179261. It offers the advantage that the glass fleece 25 can be incorporated very well into the rigid whole, with a particularly stable sandwich as a result.

[0125] The rigid layer 21C is also not foam.

[0126] Figure 7 shows the coupling parts 7-8 similar to those in Figure 6, however, the substrate 21 is constructed differently. Substrate layers 21A and 21C are constructed similarly to layers 21A and 21C of Figure 6. However, there is a third rigid substrate layer 21D, which is also made of PVC. Substrate layer 21D contains no plasticizers or plasticizers in an amount less than just 15 phr. Furthermore, the substrate layer 21D comprises a filler proportion between 30 and 70 percent by weight. Furthermore, substrate layer 21D can comprise an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black. The total thickness T1 of substrate layers 21A, 21C and 21D is at least 2 mm. The result is that the totality of the substrate layers 21A, 21C and 21D gives a high flexural rigidity to the panel 1, which is even increased by the presence of two included glass fleeces 25A and 25B. The two glass fleeces 25A and 25B are located off-center of the panel 1 at a distance D from each other of at least 1/5 of the thickness T of the panel 1. The substrate layers 21C and 21D are made thinner than the core layer 21A, however, have a thickness of at least 1/5 the thickness of core layer 21A. The result is a particularly balanced and stable sandwich construction. Substrate layers 21A, 21C and/or 21D, as such, may comprise a plurality of substrate layers and thus be multi-layered. Substrate layer 21A, for example, may comprise a plurality of substrate layers which may or may not have a mutually different composition, such as a mutually different proportion of filler or plasticizer. The same is applicable to layers 21C and 21D and more generally to all substrate layers mentioned in this document.

[0127] The two glass fleeces 25A and 25B have a weight of less than 65 grams per square meter. This has a positive influence on the process speed and practically no detrimental influence on the dimensional stability, at least not when applying with rigid substrate layers.

[0128] Figure 8 shows a variant of Figure 7, in which the substrate 21 on the underside comprises a sound-absorbing substrate layer 21E of XPE foam. The thickness of this layer 21E is between 1 and 2 mm.

[0129] Figure 9 shows a variant of Figure 7, in which the glass fleeces 25A-25B are positioned in a slightly different way. The glass fleece 25A goes centrally through the area where the upper side 19 of the tongue 11 cooperates with the lower side 20 of the upper lip 13, while the glass fleece 25 goes centrally through the area where the locking elements 15-16 cooperate . This provides excellent horizontal and vertical locking.

[0130] Figure 10 shows a variant of Figure 9. The glass fleece 25A is similarly positioned, however, the glass fleece 25B extends uninterruptedly in the coupling part 8. It extends continuously through the lip bottom 14. This is beneficial for the strength of that lip 14.

[0131] Figure 11 shows a similar construction of the substrate 21 as in Figure 10, however, the coupling parts 7-8 have another configuration. The underside of tongue 11 is convex, while the top side of lower lip 14 is concave.

[0132] Figures 12 and 13 show two more variants, in which the lower side of the tongue 11 and the upper side of the lower lip 14 comprise a flat part.

[0133] Figures 14 and 15 show how the floor panels 1 can be attached to each other using the fold-down technique.

[0134] For this purpose, the pair of short edges 5-6 of panel 1 is provided with the coupling parts 9-10 shown in Figure 16. These are realized in the form of a hook 27 directed downwards and a hook 28 directed upwards. The downward hook 27 has a lip 29 with a downwardly directed treatment element 30, whereas the upward hook 28 has a lip 31 with an upwardly directed locking element 32. The locking elements 30 and 32 cooperate across locking surfaces 33-34 to counterbalance the spacing of hooks 27-28 in the horizontal direction. Hooks 27-28 are also provided with vertically active locking elements 35-36. The vertically active locking element 35 is made as a separate insert, which is provided in a recess 37 in the down hook 27. This recess is located partially in the rigid layers 21A and 21C. It is also possible to provide the insert 35 in the upward hook 28.

[0135] The lip 29 is formed partially from the rigid layers 21A and 21C. Lip 31 is formed entirely from rigid layers 21A and 21D. The zone where the locking elements 30 and 32 cooperate is situated entirely on the rigid layer 21a. All these measures are advantageous for the resistance of the locking. The area where the insert 35 cooperates with the locking element 36 is located in the more flexible layer 21B. However, it is not excluded that this last zone is located, at least partially or totally, in the rigid layers 21A and/or 21C.

[0136] The fiberglass layer 25A is located at the height of the recess 37. This provides additional stability where the floor panel, due to the recess 37, is somewhat weaker.

[0137] The fiberglass layer 25A extends continuously on the lip 31 of the upwardly directed hook 28.

[0138] Figure 17 shows a variant of Figure 16. Here, the insert 36 is provided in a recess 37 in the riser hook 28. The area where the insert 36 cooperates with the locking element 35, however, is in fact located on a rigid substrate layer, particularly rigid layer 21A. This provides very good vertical locking.

[0139] Figure 18 shows a variant of Figures 16 and 17, in which the vertically active locking elements are made from the material of panel 1. There, two pairs of vertically active locking elements are present, namely the locking elements locking surfaces 35-36, as well as locking surfaces 33-34, which provide horizontal locking as well as vertical locking. All vertical locking elements are made from rigid layers 21A and 21C. Furthermore, the glass fleece is located at the height of the zone where the locking elements 35-36 cooperate. The glass fleece 25B extends continuously across the lip 31. This makes it possible for the lip 31 to be made very stable and the risk of damaging it, for example during the elastic flexion of the lip 31 during coupling, to be very low. small, despite the recess provided on the underside of the lip 31, which recess increases the bendability of the lip 31 and thus ease of installation.

[0140] Figure 19 shows a variant of Figure 18, in which the vertically active locking elements 35-36 are located at the end of the lip 31. The glass fleece 25B crosses it.

[0141] Fig. 20 depicts a method according to the fifth aspect of the invention. This method can be used to obtain the substrate construction of the panels 1 of, for example, figure 7. By means of spreading treatments in succession, rigid substrate layers 21D, 21A and 21C are provided. Its rigid thermoplastic material is spread over a conveyor belt 39 by means of spreading devices 38. On the spread layers 21D and 21A, a glass fleece 25B and a glass fleece 25A are provided, respectively. For this purpose, the glass fleeces 25A and 25B are unwound from the rollers 40 and fed onto the respective substrate layers 21D and 21A. The subsequently formed complex is conveyed to a double belt press 41, on which it is consolidated under the influence of pressure and/or heat. The press device 41 comprises, in the conveying direction, heating elements 42, a roller S 43 and cooling elements 44. The heating elements 42 heat the complex brought to the press device 41, as a result of which the individual layers can be connected to each other more easily and better. The use of roller S 43 is advantageous, as it provides calibration of the respective layers. Cooling elements 44 finally cool the consolidated complex so that it can be processed more quickly. Cooling elements 44 finally cool the consolidated complex so that it can be processed more quickly. Subsequently, the more flexible substrate layer 21B is provided in the consolidated set by means of a calendering device 45 consisting of more than one calendering roll 46.

[0142] It is clear that in subsequent steps the decoration support 22 with decoration 2, the wear layer and the varnish layer 23 and 24 can be applied.

[0143] Figure 21 shows a variant of Figure 20. Here, the glass fleece 25 is placed in contact with a pressing element in the pressing device 43. This differs from Figure 20, where each glass fleece is confined between rigid substrate layers.

[0144] Figure 22 shows another alternative way of providing a glass fleece 25 on a rigid substrate layer. The reference numeral 47 indicates an extruder with which the rigid substrate layer 21A is manufactured. This substrate layer 21 is subsequently conveyed between guide rollers 48. Glass fleece 25 is unwound from a roller 49 and fed, between two such guide rollers, onto substrate layer 21A. Of course, this assembly can be processed further and possibly supplemented with subsequent layers of substrate and/or glass fleece. It is also noted that this technique is advantageously applied with any type of substrate layer of thermoplastic material, irrespective of whether this refers to a rigid, semi-rigid or flexible substrate layer.

[0145] The present invention is by no means limited to the above-described embodiments; on the contrary, such methods, floor panels and support material can be realized according to various variants without departing from the scope of the present invention.

Claims (10)

1. Floor panel (1) with a substrate (21) comprising thermoplastic material, a decoration (2) provided thereon and, on at least one pair of opposite edges (3-4, 5-6), coupling parts (7-8, 9-10) comprising a tongue (11), a groove (12) and locking elements (15-16) made at least partially from the substrate (21), wherein said groove (12) is delimited by an upper lip (13) and a lower lip (14) with the lower lip (14) projecting beyond the upper lip (13), wherein said locking elements (15-16) comprise a bulge ( 15) on the lower side of the tongue (11) and an upwardly directed locking element (16) on the portion of the lower lip (14) which projects beyond the upper lip (13), said coupling parts allowing to effect a mechanical locking between two such floor panels (1), wherein said locking elements (15-16) comprise cooperating locking surfaces (17-18) that counteract the separating movement of the tongue (11) and the groove ( 12) in the horizontal direction (H), and in which the upper side (19) of said tongue (11) cooperates with the lower side (20) of the upper lip (13), so as to neutralize the separation in the vertical direction (V ), characterized in that the substrate (21) comprises a rigid substrate layer (21A) of thermoplastic material, and a fiberglass layer (18) is present on the floor panel (1), the fiberglass layer (18) having a weight of less than 65 grams per square meter, in which the area where the upper side (19) of the tongue (11) and the lower side (20) of the upper lip (13) cooperate and the area where the interlocking elements (15-16) cooperate are both located wholly on said rigid substrate layer (21A). 2. Floor panel (1), according to claim 1, characterized in that the rigid substrate layer (21A) comprises plasticizers in an amount of less than 15 phr, less than 10 phr or less than 5 phr, or does not include plasticizers. 3. Floor panel (1), according to claim 1 or 2, characterized in that the thermoplastic material of the rigid substrate layer (21A) comprises PVC. 4. Floor panel (1), according to any one of the previous claims, characterized in that the rigid substrate layer (21A) is not foamy, the density of the rigid substrate layer (21A) is situated between 1300 and 2000 kg per cubic meter or between 1500 and 2000 kg per cubic meter. 5. Floor panel (1), according to any one of the preceding claims, characterized in that the fiberglass layer (18) is adjacent to the rigid substrate layer (21A). 6. Floor panel (1) according to any one of the preceding claims, characterized in that the substrate (21) comprises a second rigid substrate layer (21B) of thermoplastic material, which is preferably not foamy. 7. Floor panel (1), according to any one of the previous claims, characterized in that a second fiberglass layer (18B) is present in the floor panel (1). 8. Method for manufacturing a floor panel (1) with a substrate (21) comprising thermoplastic material and a decor (2) provided thereon, characterized in that the method comprises the following steps: providing a first rigid substrate layer (21A) of thermoplastic material by means of a first spreading treatment; providing a fiberglass layer (18) over the spread substrate layer (21A), the fiberglass layer (18) having a weight of less than 65 grams per square meter; providing a second rigid substrate layer (21B) of thermoplastic material over the fiberglass layer (18) by means of a second spreading treatment; consolidating the spread substrate layers (21A-21B) and the fiberglass layer (18) under the influence of pressure and/or heat; providing, on the second consolidated substrate layer (21B), a more flexible or more compressible substrate layer (21D) of thermoplastic material by applying this thermoplastic material in a liquid state. 9. Method according to claim 8, characterized in that the consolidation is carried out in a press device (47). 10. Method according to claim 8 or 9, characterized in that the more flexible substrate layer (21D) is provided on the second substrate layer (21D) by means of a calendering device.

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